US6964157B2 - Exhaust emission control system and method for removal and storage of vehicle exhaust gas nitrogen oxides during cold operation - Google Patents

Exhaust emission control system and method for removal and storage of vehicle exhaust gas nitrogen oxides during cold operation Download PDF

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Publication number
US6964157B2
US6964157B2 US10/109,164 US10916402A US6964157B2 US 6964157 B2 US6964157 B2 US 6964157B2 US 10916402 A US10916402 A US 10916402A US 6964157 B2 US6964157 B2 US 6964157B2
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temperature
engine
exhaust
exhaust gas
zeolite
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Expired - Fee Related
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US10/109,164
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US20030182933A1 (en
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Brad Adelman
Per Gösta Edvin Andersson
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Ricardo Inc
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Ricardo Inc
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Assigned to RICARDO, INC. reassignment RICARDO, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ADELMAN, BRAD, ANDERSSON, PER GOSTA EDVIN
Priority to US10/109,164 priority Critical patent/US6964157B2/en
Priority to JP2003579969A priority patent/JP2006509137A/ja
Priority to DE10392476T priority patent/DE10392476T5/de
Priority to AU2003222118A priority patent/AU2003222118A1/en
Priority to PCT/US2003/009729 priority patent/WO2003082446A1/en
Priority to GB0422424A priority patent/GB2402089B/en
Publication of US20030182933A1 publication Critical patent/US20030182933A1/en
Publication of US6964157B2 publication Critical patent/US6964157B2/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
    • B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
    • B01D53/9495—Controlling the catalytic process
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
    • B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
    • B01D53/9404—Removing only nitrogen compounds
    • B01D53/9409—Nitrogen oxides
    • B01D53/9431—Processes characterised by a specific device
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/10—Internal combustion engine [ICE] based vehicles
    • Y02T10/12—Improving ICE efficiencies

Definitions

  • the present invention relates generally to an apparatus and a method for the removal and storage of vehicle exhaust nitrogen oxides during cold operation. More particularly, the invention is directed to the use of a zeolite for occluding nitrogen oxides from the exhaust of a vehicle during cold operation, which nitrogen oxides are later released by the zeolite for subsequent processing by a catalytic converter as the vehicle engine warms.
  • NO x nitrogen oxide (NO) and nitrogen dioxide (NO 2 ).
  • NO x is a pollutant that can cause many problems including, but not limited to, eye, nose, and throat irritation. NO x may also combine with water to produce acids that are a component of acid precipitation. Modern automotive vehicles are fitted with an engine exhaust treatment system to alleviate these problems and comply with environmental regulations.
  • an engine exhaust treatment system will include an adsorbent for taking up unburned hydrocarbon from the exhaust.
  • the adsorbent is disposed in the exhaust piping that leads away from the engine.
  • the adsorbent attracts the unburned hydrocarbon and accumulates it in the interstitial spaces on the surfaces of the adsorbent.
  • the adsorbent physically occludes the unburned hydrocarbon until the oxidation function of a subsequent catalytic converter has reached its light-off temperature, at which point the adsorbent also attains an elevated temperature at which it releases the unburned hydrocarbon for transport to the downstream catalytic converter.
  • the catalytic converter thereafter oxidizes and converts the unburned hydrocarbon in the exhaust gas into non-polluting gases.
  • LNT lean NO x trap
  • the present invention concerns a system for controlling vehicle exhaust gas nitrogen oxides emissions during cold operation.
  • the system includes a control for changing the NO 2 /NO ratio, an occluder for storing and releasing NO x and a catalytic converter for NO x reduction.
  • the control can increase the NO 2 /NO ratio utilizing techniques such as the exhaust gas recirculation (EGR) valve, cylinder deactivation, an oxidation catalyst, a nonthermal plasma, etc.
  • EGR exhaust gas recirculation
  • the occluder can be a zeolite based adsorber and the catalytic converter can be any suitable device such as a LNT, SCR (selective catalytic reduction with N-based reductants), deNO x catalysts (either passive or with active HC injections), etc.
  • the system integrates selected characteristics of the control, the occluder and the catalytic converter to achieve significant NO x reduction during cold operation of a vehicle.
  • an apparatus for removing NO x from an internal combustion engine exhaust stream at low temperatures, and releasing said NO x back into said exhaust stream at high temperatures comprises: an adsorber housing, having an inlet and an outlet, said inlet in communication with the exhaust stream of an internal combustion engine, and said outlet in communication with an internal combustion engine catalytic converter; and adsorbent disposed in the interior of said housing, said adsorbent able to adsorb selectively NO x at temperatures below a predetermined desired high efficiency temperature (preferably about 200 degrees Celsius), and said adsorbent able to desorb NO x at temperatures above the predetermined temperature.
  • the catalytic converter can be positioned in the adsorber housing or in a separate housing.
  • a temperature of about 200 degrees Celsius is used herein as an example, the present invention is not limited to that approximate temperature.
  • the upper temperature range for zeolites to hold NO x is about 170–200 degrees Celsius and several catalyst materials will light off in that range.
  • any of various predetermined high efficiency temperatures can be selected for operation.
  • the inventive apparatus is particularly useful for removing NO x from an internal combustion engine exhaust stream and storing same during cold operation of an engine, and then re-injecting said NO x back into the exhaust stream at catalytic converter operating temperatures.
  • the engine control module receives sensor signals from a plurality of sensors that provide information about the operating conditions of the engine and the emission control system.
  • the sensors can include a mass air flow sensor (MAF), an intake manifold absolute pressure sensor (MAP), a throttle position sensor (TPS), a vehicle speed sensor (VSS), an engine RPM sensor (RPM), a temperature of coolant sensor (TMP), a heated exhaust gas oxygen sensor (HEGO), an exhaust gas temperature sensor (EGT) and a catalyst monitoring sensor (CMS).
  • the ECM can control the exhaust gas recirculation (EGR) valve and the fuel control to cause the engine to operate during cold operation to emit exhaust gases having an increased ratio of NO 2 /NO until the LNT has reached the lightoff temperature.
  • EGR exhaust gas recirculation
  • FIG. 1 is a schematic view of an apparatus for treating exhaust gas flowing from an internal combustion engine, in accordance with the present invention
  • FIG. 2 is schematic view of an alternative embodiment of the apparatus for treating exhaust gas flowing in a flow path from an internal combustion engine
  • FIG. 3 is a block diagram of an engine emission control system in accordance with the present invention.
  • the present invention is directed to apparatus for removing NO x from an internal combustion engine exhaust stream at low temperatures, and releasing said NO x back into said exhaust stream at high temperatures, comprising: a housing having an inlet and an outlet, said inlet in communication with the exhaust stream of an internal combustion engine and said outlet in communication with an internal combustion engine catalytic converter; and adsorbent disposed in the interior of said housing, said adsorbent able to selectively adsorb NO x at temperatures below a high efficiency temperature, preferably about 200 degrees Celsius, and said adsorbent able to desorb NO x at temperatures above the high efficiency temperature.
  • the adsorbent according to the present invention comprises a zeolite, which is a crystalline inorganic polymer based on an infinitely-extending tetrahedral framework of aluminum and silicon oxides.
  • the tetrahedral framework contains channels or interconnecting interstitial pathways that are occupied by cations. NO x occlusion and storage is enhanced according to the present invention when the silicon-to-aluminum ratio is low.
  • zeolites containing exchanged divalent alkaline-earth metal cations such as Ca 2+ are able to store then release NO x molecules at temperatures below then above, respectively, about 200 degrees Celsius.
  • the exchange cations useful for the practice of the present invention include hydrogen, alkali metal, alkaline earth metal, and transition metal ions.
  • Alkaline-earth metals, from which preferred cations are prepared, include calcium, barium, strontium, and radium.
  • Useful natural zeolites may include chabazite, erionite, and faujasite, while useful synthetic zeolites include A, X, and Y zeolites.
  • a preferred adsorbent is calcium exchanged Y zeolite.
  • the inventive adsorbent system operates best at a nitrogen-dioxide-to-nitrogen-oxide ratio greater than or equal to about one, based on the formation of an ion pair (NO + NO 2 ) which interacts with the ionic network of the zeolite.
  • the present invention provides apparatus adapted to be installed in the piping of an exhaust system, typically upstream of a catalytic converter such as for example a lean NO x trap (LNT), for treating the exhaust gas flowing from the discharge of an internal combustion engine.
  • a catalytic converter such as for example a lean NO x trap (LNT)
  • LNT lean NO x trap
  • the exhaust gas from a conventional internal combustion engine includes amounts of nitrogen dioxide and nitrogen oxide entrained therein that are lower than the preferred nitrogen-dioxide-to-nitrogen-oxide ratio stated above.
  • the adsorbent In operation, when the exhaust gas enters the inlet of the housing, and the adsorbent is below a temperature of about 200 degrees Celsius, the interstices on the adsorbent attract and occlude the NO x from the exhaust gas stream. Thus, the adsorbent effects bulk separation of NO x from the exhaust gas stream. As the adsorbent is heated to a temperature above about 200 degrees Celsius by the warming of the internal combustion engine exhaust gas stream, the adsorbent desorbs the NO x stored in the interstices of the adsorbent, thereby releasing the NO x for subsequent conversion to innocuous products by a downstream catalytic converter. Thus, the adsorbent undergoes thermal cycling of the adsorption-desorption process each time the internal combustion is activated from cold operation.
  • an exhaust system for example for an internal combustion engine, is indicated generally at 10 .
  • the exhaust system 10 includes an exhaust source (not shown), such as a gasoline or diesel engine that provides exhaust gas (not shown), to an upstream end 14 of an exhaust pipe 12 .
  • the exhaust gas flows within the exhaust pipe 12 in a gas flow path indicated by an arrow 18 from the upstream end 14 of the exhaust pipe 12 to a downstream end 16 of the exhaust pipe 12 .
  • Apparatus according to the present invention is indicated generally at 20 and is connected to the exhaust pipe 12 intermediate the upstream end 14 of the exhaust pipe 12 and a catalytic converter, such as for example, a lean NO x trap (LNT) 22 .
  • Apparatus 20 includes a housing 24 having an inlet end 26 and an outlet end 28 .
  • At least one adsorbent 30 having an adsorption surface 32 in the flow path 18 of the exhaust gas is disposed in the interior of the housing 24 .
  • the adsorbent 30 In operation, when the exhaust gas enters the inlet of the housing and the adsorbent 30 is below a temperature of about 200 degrees Celsius, the adsorbent 30 removes and stores the NO x in the exhaust gas when the exhaust gas contacts the adsorption surface 32 . When the adsorbent 30 is heated above about 200 degrees Celsius, the adsorbent 30 releases the NO x to the LNT 22 .
  • an exhaust system for example for an internal combustion engine, is indicated generally at 40 .
  • the exhaust system 40 includes an exhaust source (not shown), such as a gasoline or diesel engine that provides exhaust gas (not shown), to an upstream end 44 of an exhaust pipe 42 .
  • the exhaust gas flows within the exhaust pipe 42 in a gas flow path indicated by an arrow 48 from the upstream end 44 of the exhaust pipe 42 to a downstream end 46 of the exhaust pipe 42 .
  • An alternative embodiment of the apparatus according to the present invention is indicated generally at 50 and is connected to the exhaust pipe 42 intermediate the upstream end 44 of the exhaust pipe 42 and a catalytic converter, such as for example, a lean NO x trap (LNT) 52 .
  • Apparatus 50 includes an adsorbent housing 54 having an inlet end 56 and an outlet end 58 .
  • the adsorbent housing 54 and the LNT 52 are enclosed within a common housing 64 .
  • At least one adsorbent 60 having an adsorption surface 62 in the flow path 48 of the exhaust gas is disposed in the interior of the housing 54 .
  • the adsorbent 60 In operation, when the exhaust gas enters the inlet of the housing and the adsorbent 60 is below a temperature of about 200 degrees Celsius, the adsorbent 60 removes and stores the NO x when the exhaust gas contacts the adsorption surface 62 . When the adsorbent 60 is above about 200 degrees Celsius, the adsorbent 60 releases the NO x to the LNT 52 .
  • FIG. 3 An engine emission control system 70 according to the present invention.
  • An internal combustion engine 72 is provided with an intake manifold 74 and an exhaust manifold 76 .
  • a throttle (not shown) controls the amount of fresh air admitted to the engine 72 from an air source 78 such as the atmosphere.
  • a small portion of the exhaust gas flowing out of the engine 72 through the exhaust manifold 76 is returned to the intake manifold 74 through a passage 80 connected between the manifolds.
  • the amount of the exhaust gas recirculated is controlled by adjusting an exhaust gas recirculation (EGR) valve 82 .
  • the valve 82 responds to a control signal from an engine control module (ECM) 84 connected to the valve.
  • ECM engine control module
  • the ECM 84 also is connected to a fuel control 86 to generate a control signal to determine the amount of fuel delivered to the engine 72 .
  • the exhaust manifold 76 is connected to an inlet of an occluder 88 , such as one of the absorbers 30 and 60 described above.
  • An outlet of the occluder 88 is connected to an inlet of a catalytic converter 90 , such as the lean NO x traps 22 and 52 described above or any other suitable device.
  • the EMC 84 receives sensor signals from a plurality of sensors 92 that provide information about the operating conditions of the engine 72 and the emission control system 70 .
  • the sensors 92 can include a mass air flow sensor (MAF), an intake manifold absolute pressure sensor (MAP), a throttle position sensor (TPS), a vehicle speed sensor (VSS), an engine RPM sensor (RPM), a temperature of coolant sensor (TMP), a heated exhaust gas oxygen sensor (HEGO), an exhaust gas temperature sensor (EGT) and a catalyst monitoring sensor (CMS).
  • MAF mass air flow sensor
  • MAP intake manifold absolute pressure sensor
  • TPS throttle position sensor
  • VSS vehicle speed sensor
  • RPM sensor RPM sensor
  • TMP temperature of coolant sensor
  • HEGO heated exhaust gas oxygen sensor
  • EGT exhaust gas temperature sensor
  • CMS catalyst monitoring sensor
  • the ECM 84 can control the EGR valve 82 and the fuel control 86 to cause the engine to operate during cold operation to emit exhaust gases having an increased ratio of NO 2 /NO until the converter 90 has reached the lightoff temperature.
  • the thermal management capabilities of the system according to the present invention are particularly advantageous in two scenarios.
  • the zeolite material in the occluder 88 becomes filled with NO x before the light off temperature of the converter 90 is reached so that no more NO x can be removed from the exhaust gas.
  • the desorption temperature of the zeolite material in the occluder 88 will decrease while the light off temperature of the catalyst in the converter 90 will increase.
  • This second scenario creates a temperature region where the NO x is no longer held but the catalyst has not yet reached light off.
  • the operation of the engine 72 can be managed to create a rapid temperature rise in the exhaust gas to minimize the amount of NO x that will pass through the catalytic converter 90 .
  • the EMC 84 is connected to a cylinder deactivation device 94 associated with the engine 72 to typically disable one or more intake valves thereby causing the remaining cylinders to work harder and speed the temperature rise in the exhaust gas.
  • the system 70 integrates a control, an occluder and a catalytic converter to reduce nitrogen oxides emissions during cold operation of vehicle engines.
  • the control 84 utilizes engine management technology to increase the NO 2 /NO ratio of the exhaust gas exiting the engine.
  • One method of ratio control is utilization of the EGR valve 82 .
  • Another method of ratio control is utilization of the cylinder deactivation device 94 .
  • Yet other methods of ratio control can involve utilization of the ECM 84 to adjust the fuel control 86 and/or the air source 78 or insert an additive such as an oxidation catalyst or a nonthermal plasma.
  • the zeolite based occluder 88 holds the NO x below a predetermined temperature and releases the NOx above the predetermined temperature.
  • the catalytic converter 90 lights off at or below the predetermined temperature to reduce the NOx and can be a LNT, SCR or active deNOx catalyst.
  • the NO 2 /NO ratio is not required to be equal to or greater than one.
  • the NO fraction is the dominant NOx species. Any increase in the NO 2 content will increase the zeolite occluder 88 efficiency.
  • a calcium exchanged Y type zeolite will have optimum efficiency when the NO 2 /NO ratio is unity.
  • the system 70 will operate at ratios above and below unity. Any time that the catalytic converter 90 falls below the light off temperature, the system 70 will work if the occluder 88 temperature is below its NOx desorption temperature.
  • the present invention has been described in what is considered to represent its preferred embodiment. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope.
  • the present invention could be embodied as a separate vessel within the exhaust system of an internal combustion engine, or as a part of the same housing for an LNT.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Combustion & Propulsion (AREA)
  • Health & Medical Sciences (AREA)
  • Biomedical Technology (AREA)
  • Environmental & Geological Engineering (AREA)
  • Analytical Chemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Exhaust Gas After Treatment (AREA)
  • Combined Controls Of Internal Combustion Engines (AREA)
  • Solid-Sorbent Or Filter-Aiding Compositions (AREA)
US10/109,164 2002-03-28 2002-03-28 Exhaust emission control system and method for removal and storage of vehicle exhaust gas nitrogen oxides during cold operation Expired - Fee Related US6964157B2 (en)

Priority Applications (6)

Application Number Priority Date Filing Date Title
US10/109,164 US6964157B2 (en) 2002-03-28 2002-03-28 Exhaust emission control system and method for removal and storage of vehicle exhaust gas nitrogen oxides during cold operation
PCT/US2003/009729 WO2003082446A1 (en) 2002-03-28 2003-03-28 System and method for nitrogen oxides from vehicle exhaust gas
DE10392476T DE10392476T5 (de) 2002-03-28 2003-03-28 Anlage und Verfahren zum Entziehen von Stickoxiden aus Fahrzeugabgasen
AU2003222118A AU2003222118A1 (en) 2002-03-28 2003-03-28 System and method for nitrogen oxides from vehicle exhaust gas
JP2003579969A JP2006509137A (ja) 2002-03-28 2003-03-28 車両排気ガスからの窒素酸化物用のシステムおよび方法
GB0422424A GB2402089B (en) 2002-03-28 2003-03-28 System and method for nitrogen oxides from vehicle exhaust gas

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US10/109,164 US6964157B2 (en) 2002-03-28 2002-03-28 Exhaust emission control system and method for removal and storage of vehicle exhaust gas nitrogen oxides during cold operation

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US20030182933A1 US20030182933A1 (en) 2003-10-02
US6964157B2 true US6964157B2 (en) 2005-11-15

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US (1) US6964157B2 (enExample)
JP (1) JP2006509137A (enExample)
AU (1) AU2003222118A1 (enExample)
DE (1) DE10392476T5 (enExample)
GB (1) GB2402089B (enExample)
WO (1) WO2003082446A1 (enExample)

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US20090277159A1 (en) * 2008-05-12 2009-11-12 Caterpillar Inc. Selective Catalytic Reduction Using Controlled Catalytic Deactivation
US20090308056A1 (en) * 2008-06-17 2009-12-17 Robert Bosch Gmbh Procedure and device for the purification of exhaust gas
US20100050604A1 (en) * 2008-08-28 2010-03-04 John William Hoard SCR-LNT CATALYST COMBINATION FOR IMPROVED NOx CONTROL OF LEAN GASOLINE AND DIESEL ENGINES
US20100175372A1 (en) * 2009-01-09 2010-07-15 Christine Kay Lambert Compact diesel engine exhaust treatment system
US20100175371A1 (en) * 2007-07-13 2010-07-15 Emitec Gesellschaft Fur Emissionstechnologie Mbh Method for regenerating at least one particle agglomerator and motor vehicle including an exhaust gas after-treatment system
US20100266471A1 (en) * 2009-04-17 2010-10-21 Ford Global Technologies, Llc Exhaust aftertreatment system and method of treating exhaust gas
US20110138776A1 (en) * 2010-09-02 2011-06-16 Ford Global Technologies, Llc Diesel engine exhaust treatment system
US20110138777A1 (en) * 2010-10-12 2011-06-16 Hungwen Jen Diesel engine exhaust treatment system and method including a platinum group metal trapping device
US20140123631A1 (en) * 2011-05-12 2014-05-08 Ford Global Technologies, Llc Methods and systems for variable displacement engine control
US20160038876A1 (en) * 2009-04-17 2016-02-11 Johnson Matthey Public Limited Company Small Pore Molecular Sieve Supported Copper Catalysts Durable Against Lean/Rich Aging for the Reduction of Nitrogen Oxides

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JP2006029172A (ja) * 2004-07-15 2006-02-02 Hino Motors Ltd ディーゼルエンジンの排ガス浄化装置
US7797929B2 (en) * 2007-05-21 2010-09-21 Ford Global Technologies, Llc Low temperature emission control
JP4333803B1 (ja) * 2008-04-22 2009-09-16 トヨタ自動車株式会社 内燃機関の排気浄化装置
JP2011094482A (ja) * 2009-10-27 2011-05-12 Hino Motors Ltd ディーゼルエンジンの排ガス後処理装置
US8745969B2 (en) 2010-09-08 2014-06-10 GM Global Technology Operations LLC Methods for engine exhaust NOx control using no oxidation in the engine
DE102010040678A1 (de) * 2010-09-14 2012-03-15 Robert Bosch Gmbh Verfahren zur Überwachung der Schadstoff-Konvertierungsfähigkeit in einem Abgasnachbehandlungssystem
JP5351186B2 (ja) * 2011-01-25 2013-11-27 本田技研工業株式会社 内燃機関の排気浄化システム
WO2014021140A1 (ja) * 2012-08-03 2014-02-06 Ｓｅｍｉｔｅｃ株式会社 接触型赤外線温度センサ、熱機器及び排気システム
US9903248B2 (en) * 2016-04-13 2018-02-27 GM Global Technology Operations LLC Method and apparatus for exhaust purification for an internal combustion engine
US9926825B2 (en) * 2016-04-19 2018-03-27 GM Global Technology Operations LLC Method and apparatus for exhaust purification for an internal combustion engine

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AU2003222118A1 (en) 2003-10-13
DE10392476T5 (de) 2005-02-17
GB2402089A (en) 2004-12-01
US20030182933A1 (en) 2003-10-02
WO2003082446A1 (en) 2003-10-09

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